Concrete

Constructing Sustainability

Published

3 years ago

January 12, 2024

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Nikhil Bothra, Director, EPACK Polymers, brings to fore the environmental advantages of prefab building and how current challenges can be turned into opportunities.

In the face of escalating environmental challenges posed by conventional construction methods, exacerbated by factors such as the recent construction ban in Delhi due to severe air quality concerns, the imperative for a sustainable shift in building practices becomes more evident than ever. The construction industry’s significant energy consumption, substantial waste production, and contribution to CO2 emissions demand a re-evaluation of traditional approaches.
India, grappling with a staggering annual production of approximately 150 million tonnes of construction waste, shoulders a substantial burden, accounting for a substantial 35-40 per cent of the global Construction and Demolition (C&D) waste each year. This challenge is bound to intensify further with a growing population and an ever-increasing demand for housing and infrastructure in the country.
Enter prefabricated construction, often referred to as Pre-Engineered Buildings (PEBs), as a transformative solution aligning with India’s sustainable development goals. Prefabrication not only addresses environmental concerns but also presents an efficient alternative amidst the challenges posed by construction bans. As Delhi grapples with a temporary halt in construction activities to curb air pollution, the delayed project timelines underscore the urgency for resilient, eco-conscious building practices. Let us explore how PEBs can turn the current environmental challenge into an opportunity for sustainable development.
Water conservation: Traditional construction practices, deeply rooted in history, have historically often come at an environmental cost that is both significant and concerning. Traditional construction methods consume vast amounts of water for mixing concrete, curing, and other essential processes. In contrast, prefabricated construction is a game-changer as it utilises a remarkable zero per cent water during the construction phase. This is particularly significant in regions facing water scarcity, remote hilly regions where every drop counts. By eliminating water-intensive practices, PEBs help preserve this precious resource and contribute to a sustainable future.
Lower carbon emissions: One of the most compelling reasons to embrace prefabricated engineered structures is their significantly lower carbon
footprint. Traditional construction projects churn out massive waste, including surplus materials, excess packaging, and discarded debris. This waste not only strains landfills but also exacerbates environmental degradation. However, PEBs are environmentally friendly, emitting 60 per cent less carbon pollution during the construction process compared to conventional construction. This substantial reduction in emissions is achieved by streamlining the manufacturing process in a controlled environment, reducing energy consumption and minimising waste.
Shorter construction time: Time is money in the construction industry, and shorter construction periods are a win-win for both builders and the environment. Prefabricated solutions can reduce construction time by more than 50% compared to traditional construction methods. The efficiency of assembling building components in a factory
setting and transporting them to the construction site accelerates project timelines. This not only reduces the disruption caused by lengthy construction activities but also curtails associated energy and resource use.
Energy efficiency: PEBs are designed with energy efficiency in mind. The materials used in prefab construction provide superior insulation, maintaining a consistent interior temperature, regardless of external weather conditions. Also, India’s diverse climate can pose a significant challenge to the on-site construction process. Harsh weather conditions, including scorching heat, heavy rains, and extreme cold, can disrupt construction schedules, and expose a substantial energy drain by excessive heating or cooling. Prefabricated construction eliminates this issue by shifting most of the work to a controlled indoor environment. By offering enhanced insulation, PEBs contribute to significant energy savings and promote energy-efficient living by using renewable energy sources, such as solar panels or wind turbines.
Reduced material waste: The controlled environment of a factory setting ensures that PEBs have fewer defects and require fewer repairs and replacements. In contrast, traditional construction often generates considerable material waste due to on-site errors and over-ordering. PEBs’ streamlined manufacturing process significantly reduces material waste, making them a more sustainable choice. This also aligns with the global push towards responsible resource management and conservation.
Recyclability: Sustainability goes beyond the construction phase and extends to the life cycle of a building. In India, out of 150 million tonnes of construction waste every year only a mere 1% of this colossal waste is recycled, as projected by the Centre for Science and Environment (CSE). Such practices undermine the collective efforts towards a greener future and leave a lasting mark on the planet. When a building reaches the end of its life, PEBs can be dismantled, and their components can be repurposed or recycled as they are designed for disassembly and reuse. This cradle-to-cradle approach minimises a lot of waste and adds to the overall sustainability of PEBs.
Improved resource management: Prefabrication optimises resource allocation within the factory. Materials and resources are efficiently managed, reducing over-ordering and minimising resource wastage. This results in a more efficient use of resources, promoting sustainable practices and responsible resource management.
As we aim to build a greener tomorrow, embracing PEBs and sustainable practices is the first crucial step toward a responsible and eco-conscious construction industry. The choice is pretty clear, prefabricated construction paves the way for a more sustainable and efficient construction industry that safeguards our planet for generations to come.

ABOUT THE AUTHOR:
Nikhil Bothra, Director, EPACK Polymers, heads the business development of the conglomerate. He carries on the legacy of the family business. He has taken the responsibility of spearheading the company’s expansion into the prefab segment by launching a brand-new domain of infrastructure development.

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JK Lakshmi Cement to Expand EV Fleet to 120 Vehicles by March 2027

JK Lakshmi Cement has deployed more than 70 EVs across its logistics network.

Published

3 hours ago

October 30, 2026

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JK Lakshmi Cement has deployed more than 70 electric vehicles (EVs) across its logistics network and plans to increase the fleet to 120 vehicles by March 2027. The expansion is part of its decarbonisation strategy, which aims to reduce transport-related emissions and improve operational efficiency.

The company has achieved nearly 100 per cent EV-based clinker dispatches from its Sirohi plant in Rajasthan to the Kalol Grinding Unit in Gujarat. The transition marks an increased use of electric mobility for long-haul cement transportation and is intended to lower the environmental impact of logistics operations.

The existing fleet operates on routes connecting the Sirohi plant with the Kalol Grinding Unit, Palanpur Unit and Surat Grinding Unit. JK Lakshmi Cement is working with electric vehicle logistics providers SwitchLabs and Billion E to support fleet deployment and manage transportation requirements across these routes.

The company expects the planned expansion to increase the use of electric mobility throughout its logistics network for moving cement and clinker. Chairperson and Managing Director Vinita Singhania said the programme reflected the integration of sustainable practices with the company’s focus on long-term business efficiency, while describing the Sirohi–Kalol transition as an important step in its wider decarbonisation strategy.

The EV programme forms part of JK Lakshmi Cement’s green logistics and sustainability roadmap, alongside initiatives to improve efficiency and reduce emissions across its value chain. The company has set a long-term target of achieving net-zero emissions by 2047. It is part of the JK Organisation and operates integrated cement plants in Rajasthan and Chhattisgarh, along with grinding units in Gujarat, Haryana and Odisha. The company has an annual turnover of more than Rs. 60 bn, combined cement capacity of approximately 18 mn t per annum and a target to raise capacity to 30 mn t by 2030. Its portfolio includes ready-mix concrete, gypsum plaster, wall putty, primer, adhesives and fly ash blocks.

Concrete

Martin Engineering Appoints Ashwini Khunte as India General Manager

Published

10 hours ago

October 30, 2026

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Martin Engineering names Ashwini Khunte India General Manager to strengthen operations and drive growth across key bulk material handling sectors.

Pune

Martin Engineering, a global provider of bulk material handling solutions, has appointed Ashwini Khunte as General Manager of its India business, strengthening its leadership as the company expands its presence across the country’s cement, mining, steel, power and infrastructure sectors.

Khunte brings more than a decade of experience with Martin Engineering, having joined its Indian operations in 2013 as a Design Engineer, shortly after the company established its presence in the country in 2012.

A mechanical engineer by qualification, she spent her initial five years developing bulk material handling solutions in collaboration with the company’s operations team. During this period, she gained extensive experience addressing operational challenges in the steel, cement and coal industries. She subsequently moved into project engineering, managing major engineering, procurement and construction (EPC) and original equipment manufacturer (OEM) projects from initial enquiry to commissioning. Her responsibilities later expanded to overseeing Martin Engineering’s conveyor product portfolio in India, involving customer engagement, technical presentations and site visits across heavy industries.

In 2024, Khunte was promoted to Head of Sales & Marketing for the company’s Europe, Middle East, Africa and India (EMEAI) region. The position broadened her international market exposure and strengthened her strategic and commercial leadership capabilities.

Commenting on her appointment, Ashwini Khunte, General Manager, Martin Engineering India, said: “India represents a tremendous opportunity for Martin Engineering. The country’s continued investment in cement, mining, steel, power and infrastructure is creating increasing demand for safer, cleaner and more productive bulk material handling, and that’s exactly what we do. My priority will be to build on the strong foundations already established in India, while continuing to develop our people, strengthen customer relationships and bring practical solutions to the challenges faced by our industry.”

Robert Whetstone, Area Vice President – EMEAI, Martin Engineering, highlighted Khunte’s technical expertise, market understanding and leadership experience.

“Ashwini brings an exceptional combination of technical understanding, customer knowledge and commercial leadership. She has grown as Martin Engineering has grown, and has consistently demonstrated outstanding capability to transform her expertise into practical solutions. Her knowledge of the Indian market, together with her international experience, makes her ideally suited to lead our India business through its next stage of growth for years to come.”

Since establishing its Indian business in 2012, Martin Engineering has expanded its local workforce, manufacturing capabilities and dealership network. The company supplies conveyor products, transfer point solutions, material flow aids, training and technical support to bulk material handling industries. Khunte’s appointment positions the company to further strengthen customer relationships and expand its solutions portfolio in India’s growing industrial and infrastructure markets.

Concrete

CII Calls for Greater Alternative Fuel Use in Cement Industry

Published

1 day ago

October 29, 2026

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The Confederation of Indian Industry (CII), through its Green Business Centre and Energy Efficiency Council, inaugurated the 16th Conference on Alternative Fuel and Raw Material Usage (AFR) in Goa on 27 October 2026. The two-day conference brought together more than 350 industry leaders, policymakers, waste management experts and technology providers to explore strategies for accelerating alternative fuel adoption in India’s cement industry.

Held under the theme ‘Preparation for Net-Zero: Alternative Fuels & Raw Material in Cement Manufacturing’, the conference focused on reducing dependence on conventional fuels, improving waste utilisation and strengthening circular economy practices across cement manufacturing operations.

E R Raj Narayanan, Chairman, AFR Conference 2026, and Business Head and Chief Manufacturing Officer, UltraTech Cement, highlighted the industry’s progress in alternative fuel adoption. He emphasised the need to scale implementation, strengthen supply chains and extend circularity beyond fuel substitution to alternative raw materials through technological innovation and industry collaboration.

Harish Adconkar, Managing Director, Goa Waste Management Corporation, highlighted Goa’s progress in scientific waste management and refuse-derived fuel (RDF) production. He stated that approximately 765,000 tonnes of RDF had been supplied to cement plants, contributing to an estimated displacement of 320,000–560,000 tonnes of coal. He emphasised the importance of consistent RDF offtake and stronger coordination between urban local bodies, waste management agencies and cement manufacturers.

Dr L P Singh, Director General, National Council for Cement and Building Materials, identified AFR as an important opportunity for decarbonisation and resource efficiency. Drawing parallels with the industry’s successful utilisation of fly ash, he stressed the need to address quality, technological and economic challenges to expand alternative fuel adoption.

Dr Sharad P Kale, Special Advisor to the Chief Minister of Goa and former Head of Technology Transfer and Collaboration at BARC, emphasised treating waste as a resource. He highlighted decentralised biodegradable waste processing, reduced food waste and improved resource recovery as essential measures for minimising landfill dependence.

Kiran Ananth, Executive Director, Energy Efficiency, Renewable Energy and Green Entrepreneurship, CII-Green Business Centre, noted that India’s cement production reached approximately 491 million tonnes in FY2025-26, while the industry’s thermal substitution rate (TSR) stood at 7.5 per cent, with around 7 million tonnes of alternative fuels utilised annually.

He added that the industry had invested over Rs 12 billion in co-processing infrastructure during the past six years. Improving RDF supply reliability and quality assurance would be crucial to maximising the utilisation of existing infrastructure and accelerating industrial decarbonisation.

The conference also featured discussions on advanced AFR co-processing technologies, waste pre-processing solutions and industrial best practices for improving fuel substitution and resource recovery.

A publication titled ‘From Waste to Kiln: Scaling the Use of MSW-Derived RDF in Indian Cement Plants’ was launched during the inaugural session. The report identified inconsistent RDF supply and quality as major barriers to achieving higher thermal substitution rates.

According to the publication, many cement kilns already possess the technical capability to achieve higher alternative fuel substitution. However, variations in RDF availability, moisture content, particle size and calorific value continue to limit utilisation. The report emphasised the need to strengthen waste segregation, pre-processing and aggregation systems to establish reliable RDF supply chains.

The conference’s second-day agenda includes discussions on innovative domestic and industrial waste management solutions, alternative raw materials for low-carbon cement and strategies to increase alternative fuel utilisation across India’s cement manufacturing sector.